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Old 09-20-2017, 08:37 AM   #1
Mini-Skoolie
 
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Join Date: Feb 2016
Location: Asheville, NC
Posts: 43
Year: 2001
Coachwork: Blue Bird
Chassis: International
Engine: Dt 466e
In-frame attempt on a DT-466

So my bus conversion has been on a long hiatus, which is such agony when you want to get her up and flying.

The long story is that I was taking the bus to get it weighed before we started building the interior. (Mainly out of curiosity) and our engine threw up! I checked the dipstick, saw the classic chocolate milkshake, and suspected coolant dumped into the oil pan. We took her to the mechanic and they confirmed that we had liner seals fail on the #6 and #4 pistons. Since they were going to break down the engine to get to the seals they wanted to go ahead and do an in frame while they were in there. Sounded good to me, who doesn't want a new engine? But the labor cost of $4,305 didn't sound as great. I don't mind spending a couple thousand on parts but rush truck center wanted $8,923.41 for the total cost of the job!

The short story, I would like to attempt an in frame rebuild at best or at least replace my piston liners on my own. So this is where I ask for your help team!

If anyone has any documents, youtube videos, or schematics that would help me in this endeavour I would be greatly appreciative. Also, could anyone make list of tools needed for this pursuit? I have most basic tools but I know I may need to purchase some more specialized items.

My bus is a 2001 bluebird with the lovely DT-466e. It is a conventional dog nose so I've got easy access.

As I rebuild I'm going to do my best to document the repair job and post it here for use by fellow skoolies who may want to do the same thing in the future.
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Old 09-20-2017, 10:20 AM   #2
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Join Date: Dec 2016
Location: Anaconda,MT
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Year: 1995
Coachwork: Amtran
Chassis: International
Engine: DT466 Turbo
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I am curious as to the back story, how many miles, did you check coolant did it overheat etc. What lead up to the failure? Is is a new bus to you and maybe had these problems before hand?

Anyway I will be following along to this thread, I have often wonder about how to in frame a DT466 and if it's something I could do.
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Old 09-20-2017, 10:58 AM   #3
Mini-Skoolie
 
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Join Date: Feb 2016
Location: Asheville, NC
Posts: 43
Year: 2001
Coachwork: Blue Bird
Chassis: International
Engine: Dt 466e
So we bought the bus last November and drove it 5 hours from northeastern Kentucky back to western North Carolina with no problems. For the most part it stayed parked over the winter while we worked on the interior gutting. We moved it a couple times just to get it closer to power outlets and the like, these moves would have only been a matter of yards though. When I was taking the bus to the closest scales which are only about 5 miles away I noticed the check oil/overheating lights at mile 3 and immediately pulled over. I know from the evidence left behind from the engine puke tube that it had dumped closer to the beginning of the trip.

So maybe the rings failed over the winter? I'm really not sure.
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Old 09-20-2017, 01:49 PM   #4
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Join Date: Feb 2016
Location: Indianapolis, IN
Posts: 155
Year: 1999
Coachwork: AmTran
Chassis: International FE
Engine: DT466E
Rated Cap: 84 passengers
This is certainly something you can do! Your biggest obstacle is getting the old liners out. You may be able to find a used tool on eBay that is purpose built for the job. But you could also make a liner puller yourself. Just spend some time browsing the web and youtube and you'll quickly figure out what you would need to do in order to make one.

Depending on how many miles your engine has on it you could potentially just replace the o-rings on the liners and pop them back in. But if you're going to all of the effort and you've got a good amount of miles on your engine (or cavitation on your liners) you should probably go ahead and install a new in-frame rebuild kit. Finding a manual will make the job easier if you know all the proper tolerances and torque specs. I believe the manual you want is EGES-210.
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Old 09-20-2017, 02:50 PM   #5
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Join Date: May 2016
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From what I understand, there's really only 2 major challenges on this rebuild. First, the head is *HEAVY* and like 6 feet off the ground. You'll need some way to manhandle it off the engine and to the ground. Second, as Rensch said, removing the cylinder liners (usually with pistons still in them, I think). I do believe everything else is within the grasp of a do-it-yourselfer. You'll want to go ahead and get the head reworked (or exchange it for one) while it's off.
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Old 09-20-2017, 02:56 PM   #6
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Location: Indianapolis, IN
Posts: 155
Year: 1999
Coachwork: AmTran
Chassis: International FE
Engine: DT466E
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I believe the pistons and connecting rods will have to come out before you pull the liners. Most pullers work by pulling up from the bottom of the liner so you obviously can't have anything in the way.
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Old 09-20-2017, 07:47 PM   #7
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Join Date: Aug 2017
Location: Houston, TX
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Year: 1999
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Engine: 3800 T444E
Rated Cap: 72
From taking things apart - printers, laptops, computers, and electronics... take pictures... before you remove each part of how it was before, what fasteners you removed, and when you figure out the not so obvious step... take pictures.

At least when reassembling you'll now have a reference.
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Old 09-20-2017, 09:58 PM   #8
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Join Date: Nov 2016
Location: Alberta
Posts: 134
Year: 1996
Coachwork: Thomas 72 passenger
Chassis: International 3800
Engine: 230HP DT466 engine MD3060 transmission
I just did mine..... It would be best if you have a garage to work in or at least a concrete pad. If you have some experience rebuilding engines, good. But if not, its not for a do it yourselfer. Feel free to ask me any questions. I documented some of it here. The Bus Life | Good News Bus: Forum
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Old 09-20-2017, 10:02 PM   #9
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Liners or sleeves. Pretty much the same. We used a sleeve pullers on my dad's v8 60 hp flathead fords built up to about 400 hp n his50's Midget Race car.

You will need some certain tools but you can do it. Nothing more than a big truck.


In Costa Rica they send out trucks with tons of tools ,parts and huge fitted tents over a broke down semi truck on a mountain rd.
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Old 09-21-2017, 09:10 AM   #10
Mini-Skoolie
 
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Join Date: Feb 2016
Location: Asheville, NC
Posts: 43
Year: 2001
Coachwork: Blue Bird
Chassis: International
Engine: Dt 466e
So the engine has about 132,000 it was retired from the school system in Kentucky where we bought it but it was sold to a guy that sells farm equipment. He was going to try to sell it to a church but no one was biting so we swooped in and snatched her. She came with all the service records and documentation from the school which was also nice. Luckily I'm pretty handy and have experience working on cars and motorcycles why not add diesels to the list eh?

I do have a 2 door basement garage with plenty of workbench space and a big concrete pad in front. The first order of business is moving the bus in front of one of the bays. Normally this wouldn't be a problem as I know how to cage the brakes. However, there are two complications, the first is that I have to replace the driver side steer tire. The tow truck driver, as talented as he was, managed to run it over a piece of rebar coming up the driveway. The second is the grade on which it ended up being parked, welcome to the mountains WNC! Although, really, the hill isn't too bad, I just have to be careful.

All I know is I will have enough stories to write a great book series from this bus experience. We have been calling her Sister Golden Hair Surprise after the America song. She definitely keeps us on our toes.
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